Truss mount bracket for roof anchors and related systems and methods

ABSTRACT

A roof anchor-bracket having a base plate, a riser and a top fixture, wherein the base plate comprises at least two opposed, substantially vertical flanges sized and configured to attach to at least two corresponding opposed, substantially vertical sides of support structures in a roof and wherein the top fixture contains at least one attachment element sized and configured to hold and anchor a user lifeline.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of copending U.S. Provisional Patent Application Ser. No. 61/821,982, filed May 10, 2013, which application is incorporated herein by reference in its entirety.

BACKGROUND

Commercial Roof Anchors (CRA) are a generic design fall protection roof anchor used for personal fall protection by construction and maintenance workers exposed to fall hazards; such CRAs provide attachment points for worker's lifelines. CRAs have a three component design: 1) base plate, 2) riser, and 3) top fixture.

CRAs are manufactured using various dimensions for those three components as desired to meet the design of a particular roofing system, framing configuration and engineering requirements. For example, the riser dimension may be scaled to allow the base plate to be attached to the framing substrate whereas the riser height may be lengthened to accommodate rigid insulation applied over the substrate while preserving the serviceable portion of the riser above the finished roofing membrane, thus allowing access to connect a fall protection device. These types of anchors have been manufactured for at least 20 years by many different manufactures. CRA anchors are typically installed onto commercial roof structures that are flat or low slope. The base plates are engineered to be attached to wood substrates, metal roof decking (not metal roofing panels) or may be bolted to wood or metal structural beams. The riser component is often field welded to a steel structural member without a base plate.

Traditional CRA anchors are now being adapted to multi-family and residential construction. However, these types of structures often have roof systems that are sloped and highly visible, and utilize different substrates than commercial work. This creates a problem with the installation of standard CRAs, which requires the base plate to be attached to the top surface of the substrate which in turn is attached to the supporting structure, for example wood I-Joist trusses with ¾″ substrate. Traditional CRAs are manufactured with standard size base plates, usually 16″×16″ and ¼″ or more in thickness. The base plate dimension is engineered to be attached flat against to ⅝″ or ¾″ thick plywood or to a B-Type metal deck panel, as shown in FIG. 1. About 40 fasteners are required to provide adequate strength for personal fall protection.

One problem with these traditional CRAs is that the base plate design sits on top of the substrate and the attachment method (about 40 fasteners) results in an anchor installation that protrudes so far above the finished roofing membrane that the protrusion is not acceptable in applications where the roofing is highly visible or when rigid roof panels are installed over the substrate. In addition, multi-family and residential construction utilizes 7/16″ OSB (oriented strand board) substrates in lieu of the ⅝″-¾″ CDX plywood substrates required for commercial CRA installations, and such OSB substrates may not be of adequate strength to provide for personal fall protection.

Thus, there has gone unmet a need for improved devices, systems and/or methods that provide for strong, secure attachment of CRAs to roofing trusses, joists, chords, etc., adequate for safe and secure fall protection for workers.

The present systems and methods, etc., provide one or more of these and/or other advantages.

SUMMARY

The present systems, devices and methods, etc., provide roof anchor-brackets and bases that remedy one or more of the problems above and/or other issues that arise with existing roof anchor anchors. In one aspect, the current devices, systems, etc., provide a base plate with one or more side-attachment elements, such as at least two opposed, substantially vertical flanges, configured to nest between and attach to two (or more) top trusses or similar building components that are below the surface sheeting of the roof such as roofing membranes. Although the base plate is sometimes referred to herein as a “truss-mount” bracket, the base plate with side attachment elements can be attached to any suitable structural element(s) of the building that permit the roof anchor-bracket to reside under the ultimate surface sheeting and that provide adequate strength and security to withstand free fall forces created in arresting the fall of a human subject in a free fall. The truss-mount bracket can be nested between substantially flat vertical sides of such suitable structural elements, or the vertical sides can be curved or angled or otherwise shaped as desired.

In one embodiment, a base plate of a pre-existing roof anchor can be considered an upper base plate and can be bolted or otherwise securely attached to a lower base plate comprising a bridge section holding the upper base plate and spanning between the at least two opposed, substantially vertical flanges, thereby providing a secure attachment point for existing roof anchors despite the lack of suitable attachment points in many building types such as residential houses.

In a further embodiment, the base plate with one or more side-attachment elements comprises a permanently attached riser, e.g., a riser installed directly on the bridge of the base plate such as by welding at the factory.

Thus, the roof anchor-bracket can be produced in a variety of embodiments such as:

-   -   A. A roof anchor-bracket that comprises pre-manufactured roof         anchors that are attached in the field to the bracket base         plate, for example bolted or field welded to the bracket base         plate.     -   B. A roof anchor-bracket with the riser directly attached, such         as factory welded, i.e., securely and/or permanently attached,         to the bracket base plate.

In some embodiments, the bracket portion of the roof anchor-bracket is configured for use with multi-family, residential and light commercial structures utilize wood frame construction. The roof anchor-bracket and thus the roof anchors are usually attached to the top chords, I-Joists or rafters with a wood substrate to provide a finished surface to which the roofing membrane is attached.

The roof structures can be flat, sloped or pitched.

In some further embodiments roof anchor-brackets can include:

a) The roof anchor-bracket is designed to nest between framing top chords which are usually set at 24″ on center. The roof anchor-bracket side-attachment elements, which can be referred to as legs or flanges in some embodiments, may be attached through the vertical sides of the top chords with bolts or wood screws designed for this type of installation and engineered to provide the structural strength required for a fall protection system.

b) The roof anchor-bracket installation and design can result in a base plate elevation that sits below the underside of covering substrate, such as a wood membrane, thus allowing all types of roofing membranes to be installed without the anchor base plate protruding above the substrate.

c) Utilizing two legs or flanges perpendicular to the base plate joins two top chords to create a strong attachment that would not be possible with previous anchor types that attach to a single top chord. The additional strength produced by a two top chord attachment means the roof anchor-bracket and accompanying roof anchor can be used for horizontal lifeline systems on structures built with rafter or truss top chords.

d) The roof anchor-bracket base plate can be manufactured with bolt hole locations (or other riser attachment points) that correspond to the standard roof anchor base plate bolt hole designs. This feature allows, for example, for the following:

-   -   i) Any standard roof anchor can be bolted to a lower-plate roof         anchor-bracket.     -   ii) The lower-plate roof anchor-bracket can be rotated, such as         90°, so the attachment point for user's lifeline, such as a top         loop fixture, can be aligned for single or multiple anchor use.         The roof anchor-bracket and roof anchor can be, for example,         vertical relative to the ground, parallel to the slope of the         roof, or perpendicular to the slope of the roof. Thus, the top         loop fixture can be oriented either perpendicular or parallel to         the slope of the roof or the ground, as desired.     -   iii) The roof anchor-brackets, for example with a non-permanent         roof anchor attachment system such as bolts, allows for damaged         anchors to be easily replaced, upgrade or otherwise changed as         desired by the user.

Note: for some Horizontal Lifeline Systems (HLLS) roof anchors are spaced about 20 feet on center with the end anchors' top loops parallel with the HLL and the intermediate roof anchors top loops perpendicular to the HLL.

The roof anchor-brackets herein allow altering, and/or removal of, roof anchors of varying riser heights to be attached to the base plate with the top loop of any orientation desired.

In another embodiment, the roof anchor-brackets, including the roof anchors if desired, can be configured as commercial roof anchor-truss mounts, which means a device configured for use with traditional commercial building materials and specifications. For example, this embodiment of the roof anchor-brackets can be manufactured with the riser pre-attached to the roof anchor-bracket base plate.

Exemplary features of such roof anchor-bracket devices can include:

The riser's top loop orientation can be vertical or horizontal.

The riser angle relative to the base plate and/or the roof can be varied to accommodate all sloped surfaces.

In a further embodiment, the anchors can be configured as residential roof anchors (RRA), which indicates a smaller scale version of the commercial roof anchor anchors. This means the roof anchor-bracket is a device configured for use with traditional residential building materials and specifications. For example, this embodiment of the roof anchor-brackets can be manufactured with the riser and/or base plate having a smaller diameter and with the riser heights lower in order to reduce visibility from the ground.

Because residential type projects are not suitable for installing a roof anchor base plate onto the top of the sheathing (substrate), the roof anchor-brackets herein can be provided as a one or two piece system: a) roof anchor-bracket with the residential-configured roof anchor riser as a separate component bolted onto the roof anchor-bracket, or b) a version whereby the riser is factory welded or otherwise pre-attached directly onto the roof anchor-bracket base plate.

Thus, the combination roof anchor-bracket and compatible RRA and roof anchor bolt-on base plates can provide off-the-shelf systems that replace costly custom manufacturing methods currently in use. For example: A user may want a roof anchor made to a 5/12 degree slope to be installed on a residential structure. Previously, two complicated maneuvers were required: a) design, quote, and build an anchor, which may require making an engineering stamp, and b) the project architect or engineer would design an attachment method which usually required extensive framing in order to support the fall protection load.

The roof anchor-bracket method and systems with interchangeable roof anchor and RRA can be manufactured as a two or more component system, or the systems can comprise a single design that can be mass produced and inventoried.

Roof anchor-brackets for sloped situations can be made wherein risers are cut from pre-manufactured risers allowing mass production at a lower cost. For example, the riser base can be cut off at the specified angle and welded either to a roof anchor-bracket or to its own bolt attach mounting plate.

These and other aspects, features and embodiments are set forth within this application, including the following Detailed Description and attached drawings. Unless expressly stated otherwise, all embodiments, aspects, features, etc., can be mixed and matched, combined and permuted in any desired manner. In addition, various references are set forth herein, including in the Cross-Reference To Related Applications, that discuss certain systems, apparatus, methods and other information; all such references are incorporated herein by reference in their entirety and for all their teachings and disclosures, regardless of where the references may appear in this application.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a side plan view of a roof anchor-bracket as discussed herein wherein the riser projects directly from the base plate.

FIG. 2 depicts a front plan view of a base plate of a roof anchor-bracket as discussed herein wherein the base plate forms a lower base plate configured to accept an upper base plate containing a riser.

FIG. 3 depicts a side plan view of a base plate of a roof anchor-bracket as discussed herein wherein the base plate forms a lower base plate configured to accept an upper base plate containing a riser.

FIG. 4 depicts a front plan view of a base plate of a roof anchor-bracket as discussed herein wherein the riser projects directly from the base plate.

FIG. 5 depicts a side plan view of a base plate of a roof anchor-bracket as discussed herein wherein the riser projects directly from the base plate.

FIG. 6 depicts a top plan view of a base plate of a roof anchor-bracket as discussed herein wherein the base plate forms a lower base plate configured to accept an upper base plate containing a riser.

FIG. 7 depicts a perspective view of a roof anchor-bracket as discussed herein comprising a lower base plate, upper base plate and riser, wherein the roof anchor-bracket is attached between two corresponding opposed, substantially vertical sides of support structures in a roof.

FIG. 8 depicts a perspective view of a roof anchor-bracket as discussed herein comprising wherein the riser projects directly from the base plate, wherein the roof anchor-bracket is attached between two corresponding opposed, substantially vertical sides of support structures in a roof and the riser extends at an acute angle relative to the base plate.

FIG. 9 depicts a perspective view of a roof anchor-bracket as discussed herein comprising wherein the riser projects directly from the base plate, wherein the top loop is in a horizontal position.

DETAILED DESCRIPTION

Turning to the Figures, FIG. 1 depicts a roof anchor-bracket 2 as discussed herein wherein the riser 6 projects directly from the base plate 4. In FIG. 1, the riser 6 comprises a top fixture 8 containing at least one attachment element 16 is sized and configured to hold and anchor a cable 18. “Cable” as used herein means any retention mechanism such as a long, thin rope, wire string, wire cable, but the one attachment element 16 can also be able to attach to carabiners or other devices attached to a user's lifeline. Often, the cable will be either the user's lifeline itself or an intermediate device attached to the user's lifeline such as a guide cable threaded through a plurality of roof anchor-brackets 2 so that the user's lifeline can slide along the guide cable, and/or which guide cable can hold multiple user's lifelines.

The roof anchor-bracket 2 including riser 6, top fixture 8, attachment element 16 and cable 18, must be of adequate strength to provide personal fall protection levels of security final office action a user of the device. In other words, the devices, systems, etc., herein must be able to withstand fall-restraint-level force loads and thus such a device must meet US federal and/or ANSI fall-arrest standards in force as of Jan. 31, 2014, such as OSHA 1926:502 (1995), ANSI Z359.1-07 (2007), or ANSI Z359.1-07 (2014). Some examples of such standards can be found, for example, at https://www.osha.gov/pls/oshaweb/owadisp.show_docurnent?p_id=10758&p_table=STANDARDS, or http://webstore.ansi.org/RecordDetail.aspx?sku=ANSI%2FASSE+Z359.1-2007&keyword=_inurl:webstore.ansi.org%23inurl:sku%3Dansi&source=google&adgroup=ANSI-Standards&gclid=CMOwpJ2TqbwCFc5hfgodnXgAJA. A fall-arrest anchor has a 5,000 lb (22.5 kN) breaking strength. It is also important to assure that a fall-arrest anchor is not re-used after it has already caught a worker that fell from a structure. This is important because the material of the fall-arrest anchor and/or the material of the structure being built may not “hold up” if a worker has a second fall.

The base plate 4 comprises at least two opposed, substantially vertical flanges 10 sized and configured to attach to at least two corresponding opposed, substantially vertical sides of support structures 12 such as trusses in a roof 14 (shown in later Figures).

The base plate 4 is comprised of upper base plate 20 that is typically substantially flat and is attached in turn in a substantially flat manner atop a lower base plate 4, and wherein the riser 6 extends upwardly from the upper base plate 4, and the lower base plate 4 comprises a bridge section 24 holding the upper base plate 4 and spanning between the at least two opposed, substantially vertical flanges 10. In the embodiment shown in FIG. 1, base plate 4 is comprised of a single piece of material 26 forming both a base for the riser 6 extending directly from the single piece of material 26 and the bridge section 24 spanning between the at least two opposed, substantially vertical flanges 10.

The roof anchor-bracket 2 can be made of any suitable material such as steel 28, or any other desired metal, polycarbonate, Kevlar, etc, such as A-36 steel.

the at least two opposed, substantially vertical flanges 10 comprise side attachment holes 34 sized and configured to accept at least one of bolts, nails or screws to attach the at least two opposed, substantially vertical flanges 10 to the opposed vertical sides of the at least two opposed wood trusses 32.

The at least one attachment element 16 of the top fixture 8 can be a top loop 30 sized and configured to hold a cable 18. The top loop 38 can be closed as in FIGS. 1 and 7 or open as in FIGS. 8 and 9. Any suitable one attachment element 16 can be used including for example carabiners, clamps, etc., provided that the fall-protection of the device is maintained.

FIG. 2 depicts a base plate 4 of a roof anchor-bracket 2 as discussed herein wherein the base plate 4 forms a lower base plate 4 configured to accept an upper base plate 4 containing a riser 6. In this Figure, as well as FIGS. 3-5, the Figures include some exemplary dimensions suitable for the roof anchor-bracket 2 to be attached between two trusses spaced apart in a normal manner in a standard building roof.

FIG. 3 depicts a base plate 4 of a roof anchor-bracket 2 as discussed herein wherein the base plate 4 forms a lower base plate 4 configured to accept an upper base plate 4 containing a riser 6.

FIG. 4 depicts a front plan view of a base plate 4 of a roof anchor-bracket 2 as discussed herein wherein the riser 6 projects directly from the base plate 4.

FIG. 5 depicts a side plan view of a base plate 4 of a roof anchor-bracket 2 as discussed herein wherein the riser 6 projects directly from the base plate 4.

FIG. 6 depicts a top plan view of a lower base plate 22 of a roof anchor-bracket 2 as discussed herein. In particular, lower base plate 22 is configured to accept a substantially flat upper base plate containing a riser. The upper base plate attachment holes 40.

FIG. 7 depicts a perspective view of a roof anchor-bracket 2 as discussed herein comprises a lower base plate 4, substantially flat upper base plate 20 and riser 6. The roof anchor-bracket 2 is attached between two corresponding opposed, substantially vertical sides of support structures 30 in a roof 14. The support structures 30 in the roof 14 can be opposed vertical sides of at least two opposed wood trusses 32 and the at least two opposed, substantially vertical flanges 10 are sized and configured to attach to the opposed vertical sides of the at least two opposed wood trusses 32, in this case held in place with screws 42. Non-opposed structures can also be used as desired provided that the elevation of the roof anchor-bracket 2 relative to the roof 14 including a roofing membrane 36.

FIG. 8 depicts a perspective view of a roof anchor-bracket 2 as discussed herein comprises wherein the riser 6 projects directly from the base plate 4. The roof anchor-bracket 2 is attached between two corresponding opposed, substantially vertical sides of support structures 30, in this case held in place with bolts 44. The riser 6 extends at an acute angle relative to the base plate 4. In the embodiment shown, the acute angle A between the riser 6 and the base plate 4 is substantially identical to the angle A between wood truss 32 and horizontal, to give a riser 6 that is vertical relative to gravity. If desired, other angles relative to gravity and/or the trusses can be used.

FIG. 9 depicts a perspective view of a roof anchor-bracket 2 as discussed herein comprises wherein the riser 6 projects directly from the base plate 4, wherein the top loop is in a horizontal position. This demonstrates that the riser 6 can be rotated to any desired direction to assure that the opening of the top fixture 8 is oriented in such desired direction. This can facilitate use of multiple roof anchor-brackets 2 in series, either in a line or in a geometric shape.

In further aspects, the discussion herein provides methods of making and of using the fall-arrest anchors, anchor systems and anchor kits herein.

In further aspects, the discussion herein provides methods of making and of using the roof anchor-bracket 2.

Also provide herein are fall-arrest anchor kits and systems comprising a roof anchor-bracket 2 as discussed herein as well as suitable components such as fastening devices such as screws 42, bolds 44 and if desired a worker's lifeline. The fall-arrest anchor systems also comprise the roof anchor-bracket 2 attached to a roof and/or building and/or to a worker's lifeline. The kits can also comprise a roof anchor-bracket 2 configured as solely a lower base plate 22 with two opposed, substantially vertical flanges 10, etc., to be later coupled with an upper base plate carrying one or more risers.

All terms used herein are used in accordance with their ordinary meanings unless the context or definition clearly indicates otherwise. Also unless expressly indicated otherwise, in the specification the use of “or” includes “and” and vice-versa. Non-limiting terms are not to be construed as limiting unless expressly stated, or the context clearly indicates, otherwise (for example, “including,” “having,” and “comprises” typically indicate “including without limitation”). Singular forms, including in the claims, such as “a,” “an,” and “the” include the plural reference unless expressly stated, or the context clearly indicates, otherwise.

The scope of the present devices, systems and methods, etc., includes both means plus function and step plus function concepts. However, the claims are not to be interpreted as indicating a “means plus function” relationship unless the word “means” is specifically recited in a claim, and are to be interpreted as indicating a “means plus function” relationship where the word “means” is specifically recited in a claim. Similarly, the claims are not to be interpreted as indicating a “step plus function” relationship unless the word “step” is specifically recited in a claim, and are to be interpreted as indicating a “step plus function” relationship where the word “step” is specifically recited in a claim.

From the foregoing, it will be appreciated that, although specific embodiments have been discussed herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the discussion herein. Accordingly, the systems and methods, etc., include such modifications as well as all permutations and combinations of the subject matter set forth herein and are not limited except as by the appended claims or other claim having adequate support in the discussion and figures herein. 

1. A roof anchor-bracket comprising a base plate, a riser and a top fixture, wherein the base plate comprises at least two opposed, substantially vertical flanges sized and configured to attach to at least two corresponding opposed, substantially vertical sides of support structures in a roof and wherein the top fixture contains at least one attachment element sized and configured to hold and anchor a user lifeline.
 2. The roof anchor-bracket of claim 1 wherein the base plate is comprised of a substantially flat upper base plate attached substantially flat atop a lower base plate, and wherein the riser extends upwardly from the upper base plate, and the lower base plate comprises a bridge section holding the upper base plate and spanning between the at least two opposed, substantially vertical flanges.
 3. The roof anchor-bracket of claim 1 wherein the base plate is comprised of a single piece of material forming both a base for the riser extending directly from the single piece of material and a bridge section spanning between the at least two opposed, substantially vertical flanges.
 4. The roof anchor-bracket of any one of claims 1 to 3 wherein the roof anchor-bracket is made of steel.
 5. The roof anchor-bracket of any one of claims 1 to 3 wherein the support structures in the roof are opposed vertical sides of at least two opposed wood trusses and the at least two opposed, substantially vertical flanges are sized and configured to attach to the opposed vertical sides of the at least two opposed wood trusses.
 6. The roof anchor-bracket of claim 5 wherein the at least two opposed, substantially vertical flanges comprise holes sized and configured to accept at least one of bolts, nails or screws to attach the at least two opposed, substantially vertical flanges to the opposed vertical sides of the at least two opposed wood trusses.
 7. The roof anchor-bracket of any one of claims 1 to 3 wherein the at least one attachment element of the top fixture comprises a loop top sized and configured to hold a cable.
 8. The roof anchor-bracket of claim 7 wherein the loop top orientation is vertical.
 9. The roof anchor-bracket of claim 7 wherein the loop top orientation is horizontal.
 10. The roof anchor-bracket of claim 7 wherein the loop top is a closed loop.
 11. The roof anchor-bracket of claim 7 wherein the loop top is an open loop.
 12. The roof anchor-bracket of any one of claims 1 to 3 wherein the cable is a wire cable. 